Coating and printing process and apparatus therefor



March 15, 1932. N. L. CAMPBELL 1,849,275

COATING AND PRINTING PROCESS AND APPARATUS THEREFOR Filed June 19. 1926I 2 Sheets-Sheet 1 Illlllllll llllllllll &

fislllla Illlllllll INVENTOR 4% BY mm X I V ATTORNEY 2 Sheets-Sheet 2INVENfOR a, (.1 W MAM 5 ORNEY March 15, 93 N. 1.. CAMPBELL COATING ANDPRINTING PROCESS AND APIARATUS THEREFOR Filed June 19, 1926 B product.The quality of this type Patented Mar. 15, 1932 UNITED STATES PATENTOFFICE NEIL L. CAMPBELL, OF GLENDALE, OHIO,

ASSIGNOR, BY MESNE ASSIGNMENTS, TO

CARTEAGE MILLS INCORPORATED, OF CINCINNATI, OHIO, A. CORPORATION 013OHIO COATING AND PRINTING PROCESS AND APPARATUS THEREFOR Applicationfiled June 19,

My present invention relates to the manufacture of floor coverings orthe like, and has particular reference to the treatment of a basematerial of a character which is particularly adaptable to serve as afloor covering.

The treatment of a base material so as to convert it into one type offloor covering includes the application to the base of one or morecoatings of a material such as paint, these coatings imparting to thebase an ornamental or pattern coating. I may apply this pattern coatingin different manners so as to produce at least two differing types offinished floor coverings; one wherein the top pattern or ornamentalcoating is applied over the full area of the base to constitute anunbroken upper surface; another wherein the top ornamental coating isapplied upon a base coating along predetermined areas of the latter, sothat portions of the base or'ground coating will show through andthereby constitute por-' tions of the exposed surface which has thefinished pattern thereon.

Where I have attempted to produce a floor covering according tothese twomethods, I have found that the former method produces a finished productof higher quality. I have generaly denoted this type of product as agrade A product, and in actual practice I have found it advisable to layone or more ground coatings underneath this pattern coating in spite ofthe fact that none of the ground coating will show through when theproduct is complete. The second type of product, wherein portions of theground coating show through, is generally termed by me as a grade ofproduct has been found by me to be somewhat inferior to the grade Aproduct, and I attribute the inferiority to various facts. Among theseis the fact that where the pattern coating is applied to cover onlyportions of the ground coating after the latter has become dry, an upperwearing surface is produced whose wearing qualities are obviouslyimpaired because of this fact. In the production of floor coverings ofthe type designated as grade A, I have found that an increased amount ofcoating material is necessary, because of the fact that no part of theupper- 1926. Serial No. 117,059.

most ground coating serves as the wearing surface.

' One of the objects of the present invention is to produce a floorcovering which will have the advantageous characteristics, both as towearing qualities and as to appearance, of the type heretofore known asgrade by the utilization of a method substantially like that heretoforeemployed to produce the type known as grade B. By means of my invention,I am enabled to produce a floor covering wherein a minimum of paintmaterialis necessary, and wherein only portions of the ground coatingare covered by the top pattern coating, the uncovered portions of theground ornamentation; but wherein the disadvantagenus feature of thegrade B product, such as decreased wearability, are eliminated, and theadvantageous features of the grade A product attained.

These objects I attain, in part, by applying the pattern coating to theground coating before the latter is completely dry. More particularly, Iapply the pattern coating at a time when the ground coating is stillcapable of substantial permanent distortion by pressure. In this way, Iam enabled to embed the pattern coating; and if my invention isefficiently carried out, it" is possible to embed the pattern coating toa sufficient degree so as to produce a resulting surface which is devoidof irregularities of the character heretofore typical of the grade Bproduct. In this manner, I attain the further results and advantagesflowing from the fact that the ground coating does not have to be driedbefore further treatment thereof, and that the application of thefinished pattern can be made in a process which is continuous withrespect to the application of the ground coat- Another feature of myinventionlies in applying the ground coating in'such a manner that itsexposed surface will be just as smooth and good-looking as the surfaceof the product known as grade A has been. A further feature lies inapplying the ground coating by a method which produces this advantageousresult while at the same time elimfeature of my invention to utilize amethod akin to the so-called printing or mash-block process heretoforeemployed in connection with the application of the pattern coating.

More particularly I apply the ground coating by means of a series ofapplied coatings which are laid by means of applicators, such asmash-blocks, in positions which complement each other so as to producean unbroken finished coating of the ground material.

. This method of laying the ground coating is beset with variousdifficulties; accordingly, other features of my invention lie inperforming certain steps in connection with the applicator depositionswhereby these disadvantages and difficulties are overcome. Moreparticularly, I have-found it difficult to utilize a minimum amount ofmaterial and thereby produce the thinnest possible ground coating, in amanner which will at the same time produce an absolutely smooth surfacefor the purposes hereinbefore specified. Accordingly, a feature of myinvention lies in suitably treating the applied ground coating so as tosmooth out its surface, place it in such condition that the patterncoating may be subsequently applied thereto while the ground coating isstill in a semi-dry condition, and in general, render it suitable forthe purpose of constituting a portion of the final ornamentation.

In connection with the application of the ground coating by means ofmash or printing blocks, another feature of my invention lies inutilizing mash or printing blocks whose printing or applying surfacespresent a material, such as steel, which is particularly adaptable foruse in connection with the practice of my invention.

My present invention embodies certain other advantageous features. WhereI have attempted to apply the ground coating by pouring a mass of thematerial upon the base in advance of two complementary rollers desi nedto spread the material over the base, I ave found that a large amount ofwaste occurs, and that the'applied ground coating is not suitably smoothand efliciently applied. In accordance with an object of the presentinvention, I have found it necessary to produce a ground coating ofextremely eflicient qualities; and in accordance with my method, thedisadvantages heretofore entailed by the use of the rollers referred tohave been obviated. Moreover, inasmuch as the pattern coating is appliedby mash-blocks or applicators which necessitate a step by step movementof the base, I have found it necessary heretofore to utilize twomachines, because the roller method of applying the ground coatingcould'not be effected with a step by step movement of the base. Theuti-- lization of two separate machines or sets of apparatus hasentailedexcessive handling of the material and has necessitated thecutting of the base material into lengths which could individually besubjected to the various steps of the process. In accordance with mypresent invention, I am enabled to utilize only one unitary apparatus,and I am thereby enabled to eliminate many extra steps of handling, andI am enabled to utilize the felt base ma terial in a continuous mannerwhich eliminates the necessity for cutting, and therefore effects agreat saving of time, material and labor.

A still further feature of the invention lies in applying a coating tothe under-side of the base in amanner which eliminates separatemanipulation even for this purpose,

and which therefore enables me to complete the entire operation in asingle continuous manner and by means of a unitary apparatus. Theeconomical advantages of my invention are therefore extremely obvious.

For the attainment of the foregoing objects and suchother objects as mayhereinafter appear or be pointed out, I have illus trated one embodimentof my invention in the accompanying drawings in which Figure 1 is adiagrammatic elevation view of a piece of apparatus capable ofperforming the various steps of my invention;

.Figure 2 is a plan view of a portion of a continuous roll of felt basematerial, showing the successive steps performed by correspondingiypositioned elements of the apparatus shown in Figure 1;

Figure 3 is a fragmentary perspective view of one of the printing blockswhich may be utilized for the application of the ground coating;

Figure 4 is a similar View of a complementary printing block;

Figure 5 is a fragmentary longitudinal cross-section, upon a greatlyenlarged scale, of a portion of the base material during certainintervals of the process showing diagrammatically the relative functionsof several elements of the apparatus;

Figure 6 is a fragmentary plan view of one of the elements shown inFigure 5; and

Figure 7 is a fragmentary cross-section of a portion of a completedfloor covering, showing the nature of the article which may be producedby my present invention.

Referring to the drawings, and particularly to Figure 1, I haveillustratively shown a roll of felt base material 10 mounted in anysuitable manner so as to permit free unwinding of the materialtherefrom. In the illustrated embodiment the under-side of the basestrip is coated first. Accordingly, I lead the strip of base materialfrom the roller 10 through two complementary rollers 12 and 13 of whichthe former is a pressure roller and the latter is a coating roller. Theroller 13 may be suitably supplied with the coating material from anythe reservoir 14. It will be understood that the strip of base materialwill have its underside 15 coated by virtue of its contact with theroller 13.

The strip is then fed over the guide rolls 16 and 17, the latter onethereof being preferably of a type which will positively engage and feedthe strip. In order to reverse the position of the strip before it isled through that portion of the apparatus which is designed to apply theupper coating, the strip is passed over the roller 18 mounted upon theend of a long platform or foundation 18. It will be observed that duringthe passage of the strip from the roller 13 to the roller 18, theunder-side 15 of the strip, i. e., that side which has just been coated,will be untouched by the rollers 16 and 17. For the purpose of insuringsuificiently complete dryness of the under-side 15 by the time the stripis made to pass over the roller 18, a length 20 of the strip ispermitted to hang free between the roller 17 and the roller 18. AlthoughI have shown the portion 20 as a slack portion constituting merely asingle loop, nevertheless it will be understood that any desired numberof loops may be provided for. It will be further understood that thisslack may be maintained by suitably corelating the speed of operation ofthe feeding roller 17 and the feeding roller (not shown) which draws thestrip through the main portion of the apparatus.

The strip is made to pass over the bed of the apparatus in a step bystep movement, and in passing through that portion of the apparatuswhich I have designated A, the ground coating is applied to the uppersurface of the strip; during the passage through that portion of theapparatus designated by B, the various steps for applying the patterncoating are performed.

Referring now to Figures 2, 3 and 4, It will be observed that I haveshown a printing block 26 which is provided with a series of parallelridges or printing .ribs 32, these ribs being provided with an applyingsurface of a material such as steel, and being adapted to apply a seriesof parallel transverse lines upon a predetermined area of the strip. Theapplication of these lines, as well as the application of all otherportions of the coating material, takes place during an interval of timewherein the continuous strip is momentarily stationary. This will bereadily appreciated, when'it is remembered that the entire strip is madeto pass through the apparatus in a step by step movement. After thestrip has been moved forward one step, thereby bringing the stripedportion beneath the complementary printing block 27, the latsource ofsupply, such as ter will apply a second series of parallel transversemarkings to the strip. The block 27 is provided with ribs 33 similar tothe ribs 32, and the positions of the printing blocks and of the ribsare so co-related to the step by step movement of the strip, that thesecond set of parallel markings will be applied to the parallel spaceslying between the original markings40. In this manner, a complete unbroken layer of ground coating is applied to the base material. i

I have found that by the employment of two printing blocks of thecharacter set forth, I obtain a ground coating which is not only uniformin character and which has increased wearing qualities, but which willpresent portions serving as part of the finished pattern and having allthe appearance of portions which have been applied by a pattern block.This satisfactory result I attribute also in part to the employment ofprinting blocks made of a material such as steel.

Before proceeding to describe more fully the steps which I have foundnecessary for finally completing the ground coating, I Shall brieflydescribe the steps whereby the pattern coating is "applied. As the strippasses step by step through that portion of the aparatus marked B, eachprinting block or mash-block of the set 50, 51, 52, 53 applies apredetermined series of markings upon the strip. These blocks are alsopreferably made of metal such as steel; they are substantially of thesame dimensions and character as the blocks 26 and 27, and they carryribs or configurations upon their lower surfaces which define thedifferent patterns to be applied by each. The mash-blocks are sopositioned and designed in relation to the step by step movement of thestrip that each marking will complement the mark previously applied soas to efiect a completed ornamentation in a manner illustratively shownin Figure 2. For purposes of inking these mash-blocks, as well as theblocks 26 and 27 I may employ the sliding inking members 55 which may beof the conventional character hitherto employed for this purpose, andoperating in a more or less conventional manner. It will be under, stoodthat the pattern mash-blocks 50, 51, 52 and 53 are reciprocated intime'd relation with the reciprocation of the blocks 26 and 27 and infact a single means may control the timing of all the blocks as well asthe step by step feed, because all the blocks will be raised and loweredsynchronously and the feed will have a predetermined timal relationthereto.

In Figure 5 I have diagrammatically represented, upon a large scale, themanner in which the parallel markings 40 are, in my opinion, applied.Whereas the markings of the blocks 26 and 27 should theoreticallyproduce a smooth unbroken layer of coating material, nevertheless I havefound that a perfect result may not always be obtainable. I

' have observed that when the block 26 is lifted from the strip, thesurface tension of the coating material causesit to adhere to theprinting ribs on the block as the latter is raised so that thetheoretically parallel opposite v walls of each deposited mark are madeto conthe strip. However, the theoretical parallel- 'sions 36 and 38. In

ism between the opposite sides of each applied marking will not beregained, and as a result a plurality of parallel markings will havebeen produced, having cross-sections substantially like'thoseillustrated in the right portion of Fi re 5. The upper'surface 36 ofeach marking will have a' width somewhat less than the width of theparticular rib 32 or 33 which caused its deposit, and the walls 37 ofeach marking will be somewhat concave, and will embody a certain upwardconvergence.

Referring now to the adjacent portion of Figure 5, I have illustrativelyshown what I believe occurs when the second block 27 applies its linesof coating material. A similar' adhesion between the ap'lied markingsand the printing ribs of'the lock probably occurs, but the coatingmaterial will merge with the rows of coating material which have alreadybeen deposited, and the result of all the adhesion and cohesion whichoccurs, and of the surface tension of the coating material, will be thefinal production of a. series of alternate high spots and depresorder toremedy this condition, I have found it preferable to provide a rotatableroller 39 suitably mounted to rotate in contact with the coating, but

. intermittentl in the direction indicated by the arrow, so that norelative movement will occur between the strip and the roller. In otherwords, the roller 39 remains stationary while the strip is stationary,but when the strip is moved, the roller is given a rotation justsuflicient to cause a pure rolling movement to take place between theroller and the strip. The roller 39 is so positionedas to iron out theunevennesses of the applied ground coating.

However, I have found that the roller 39 will become covered with alayer of pigment or coating material. As a result, although the coatingmaterial is ironed out, its resultant condition will still beimperfectly smooth.

.I have represented this imperfect condition by a wavy line in Figure 5,although I have found the imperfections to exist mostly as longitudinalstreaks. For the purpose of re- 7 moving this last vestige ofunevenness, I provide a second roller 41 which is designed to bestationary, and which barely touches the.

upper surface of the applied coating mate-v rial. After the strip passesunderneath the roller 41, all uneven conditions-are eliminated, and thesurface of the applied material is entirely smooth when it passes thispoint. I have found that by the treatment above outlined, the uppersurface 'of the ground coating is not only made adaptable to serve aspart of the wearing surface, but it is given a consistency and characterwhich adapts it for the successful application thereto of the port 44,the handle being provided with a pin 43 engageable in a selectedopening. By manipulating the handle, the roller 41 may be given anangular rotation about its axis,

and by suitably positioning the pin .43 in asuitable opening 42, theroller may then be locked into this new position wherein a newcontacting surface has been brought into operation. Although I do notmean to limit myself to any particular construction, I haveillustratively shown and described an arrangement of this character, andI prefer to render the roller 41 rotatable only in the directionindicated by the arrow so that impurities would not be pushed back uponthat portion of the strip which has not @t come into contact with theroller. 1

By means of my invention, I am enabled I to utilize a coating materialhaving a composition which renders it capable of drying rather quickly.This is made possible because of the extremely short intervals of timebetween which the ground coating and the pattern coating are applied. Inaccordance with an object of my invention, I control and regulate thecomposition of the coating material, and I co-relate the period ofdrying-with the distances between the elements of the apparatus in apredetermined manner, so that the coating material is in a gelatinouscondition when it passes through that portion of the apparatus marked B.The condition of the coating must be such that it may be distorted bypressure only to, a degree which will embed the applied pattern coatingat least partially into the ground coating. In other words, if theground coating has become too dry by the tlme the pattern coating isapplied, the latter will be deposited along raised portions, much inthe.

manner of the pattern coating deposit of the product heretoforeattempted by me and designated as grade B. On the other hand, if theground coating is too moist, the pressure thereon of the mash-blocks5053 will displace portions of it to an extent which will impair thesmoothness which has previously been imparted to the ground coating. Ifthe speed of drying has been properly corelated with the time intervalsof operation, the. pattern coating will be applied so as to produce aresult which is illustratively shown in Figure 7.

Referring to this figure, 10 represents the base material, 45 representsthe ground coating which has been applied thereto, and 46 represents theembedded applications of the pattern coating material. Inasmuch as thelatter is applied to a coated surface, the difiiculties encountered inthe application of the ground coating are not present, and I have foundit possible to produce a very efficient and smooth surface withoutundertaking any additional steps.

It will thus be observed that I have produced an article having all thefavorable characteristics of the product heretofore known as grade A,whereas the nature of vthe ornamentation is such as has beencharacteristic of the article heretofore known as grade B. Not only is agreat saving effected in the amount of pattern coating material, but agreat savingin the amount of ground coating material is effected becauseof the method of applying the ground coating. I therefore consider theutilization of printing blocks for the application 'of the groundcoating of extreme importance. By their use all waste is eliminated; andthe thickness of the ground coating may be accurately controlled so asto produce the thinnest possible uniform coating. A result of thischaracter has not been possible heretofore in cases where the groundcoating has been applied in quantities, and thereupon spread over thebase material by means of rollers. Moreover, it will be observed that bythe use of printing blocks for the application of the ground coating, Iam enabled to effect a great saving in time, handling, and floor space.The possibility of completing the entire process in one unitaryapparatus is of great economical importance, as will be readilyunderstood.

Furthermore, it will be observed that I have produced an article havingentirely different characteristics from either of the articlesheretofore made. Reference to Figure 7 will clearly show the salientfeatures of the present product. It will be observed that a smooth uppersurface is produced, and that portions thereof are constituted byupwardly projecting portions 47 of the ground coating material. The\vearability of a material of this character will be very great, andthis alone is a very important result which I bly. Furthermore, I haveillustrated and I described my process as performed by an apparatus inwhich both the ground and the pattern coatings are applied byreciprocating applicators, such as printing blocks, because therebycertain advantages are at tained. It nevertheless will be understoodthat as far as my herein disclosed apparatus and process for applyingthe ground coat are concerned, the broader phases of my invention areattainable even though the pattern coat is applied in a different mannerfrom that herein disclosed, as for instance by a rotary process. So alsoas far as the application of a pattern coat to a wet ground coat isbroadly concerned, the particular method of producing the latter or ofapplying the former are features that appertain to the attainment of amore or less effective practice of my invention. Where, in fact, otherapparatus such as a rotary printing process is employed for applying thepattern coating, this change in the character of the feed can becompensated for by festoon- While I have herein suggested the employmentof a ground coat applied by mash or printing blocks in which the colorof the coating material is the same so as to provide a ground coat of auniform color throughout, it will be understood that by my process andapparatus, I can have the longitudinal stripes applied by one of theprinting blocks, for instance, that numbered 26 of one color and thoseapplied by the other rinting block, for instance that numbered '2 ofanother color so that this, in connection with the rest of the mechanismwill produce a variegated colored ground coat. Where ordinary floorcovering is produced, I can take advantage of this variegated effect tohave this effect appear in the final wearing coat by properlypredeterminin g the printing mash blocks 50, 51, 52 and 53 which applythe final ornamentation and where my process and apparatus are employedfor the purposes of forming rugs, I can have the rug pattern so impresseupon this variegated ground coat so as to have the ground coat workedinto and form part not only of the field of the rug, but also of theborder.

Having thus described my invention and illustrated its use, what I claimas new and desire to secure by Letters Patent is- 1. The process ofmaking floor covering which comprises the steps of applying asubstantially parallel markings, and treating the coating to makeportions thereof suitable for constituting portions of a compositepattern coating, said treatmentcomprising the step of subjecting thecoating to a pure rolling pressurelto equalize the applied complementaryportions.

2. The process of making floor covering which comprises the steps ofapplying a ground coating to a base in complementary portions, saidportions comprising sets of substantially parallel markings, andtreating the coating to make portions thereof suitable for constitutingportions of a composite pattern coating, saltl treatment comprising thesteps of subjecting the coating to a pure rolling-pressure to level theapplied portions and then subjecting the coating to a sliding pressureto remove irregularities.

v 3. In an apparatus of the character described, means for applying aground coating to a base material, a series of pattern-coat applicators,means for moving the coated material into operative subjection to theappli- I cators, and means for smoothing the ground coating during saidmovement.

4. In an apparatus of the character described, means for applying aground coating to a base material, a series of pattern-coat applicators,means for moving the coated material into operative subjection to theappliound' cators, and means for treating the 1 coating during saidmovement, sald last named means comprising a roller adapted to applyrolling contact to the coating.

5. In an apparatus. of the character de scribed, means for applying aground coat- 7 ing to a base material, a series ofpattern-coatapplicators, means for moving the coated material into operativesubjection to the applicolor, said areas in the respectiuistations beingofl'set so as to completely co er each section with solid color, and ata succeeding station smoothin the resulting solid color, said colorbeing of relatively quick drying paint so as to be slow flowing, and instations suc-,

ceeding to the smoothing, and while the paint is still wet impressingpatterns in paint upon the solid color, with the result of impressingthe pattern coat into the solid color coat, as distinguished fromdepositing it upon the solid color coat, for the purpose described."

9. The process of making floor covering whichcomprises subjectin a basematerial to successive applications 0 ground coating, each applicatlonsimultaneously producing a series of closely interspaced coated areas,

the areas in successive app lcations being complementary, wherebyuncoated areas left by the first application are filled in, treating thecomposite complete coating thus forme to render it smooth; and printinga pattern on said ground coating before said ground coating has dried.

I In witness whereof, I have hereunto signed my name.

NEIL L. CAMPBELL.

cators, and means for treating the ground coating during said movement,said last named means comprising a roller adapted to apply rollingcontact to the coating, and a stationary pressure member adapted tosubject the coating to sliding pressure.

- 6. In an apparatus of the character described, means for applying aground coating to a base material, a-series of pattern-coat applicators,means for moving the coated material into operative subjection to theapplicators, and means for smoothing the 7 ground coating during saidmovement, said last named means comprising a stationary rollerpositioned to apply sliding pressure to the coating.

7. In an apparatus of the character described, means for applying aground coating to a base material, a series of pattern-coat applicators,means for moving the coated material into operative subjection to theapplicators, and means for smoothing the ground coating during saidmovement; said last named means comprising a stationary rollerpositioned to apply sliding pressure to the coating, and means forrotating the roller

